Removal and Replacement

Fuel Tank (Part 1):

Fuel Tank (Part 2):

Fuel Tank

REMOVAL

WARNING: Place "NO OPEN FLAMES" signs near the working area.

CAUTION: Be careful not to spill fuel.

1. Set the vehicle on a lift.
2. Release the fuel pressure.
3. Drain fuel from the fuel tank.
4. Remove the rear seat.




5. Remove the service hole cover of fuel pump.




6. Disconnect the connector from fuel pump.




7. Remove the connector (A) and clip (B).
8. Remove the service hole cover of fuel sub level sensor.
1. Remove the bolt (A).




2. Push the grommet (B) down and remove the service hole cover.

9. Disconnect connector (A) from fuel sub level sensor.




10. Disconnect the quick connector of fuel delivery hose (B) and return hose (C).
11. Remove the trunk room trim. (Sedan model).
12. Remove the rear quarter trim. (Wagon model).




13. Remove the pipe protector.




14. Remove the grommet and disconnect the quick connector of the evaporation pipe.
15. Remove the rear wheels.
16. Lift up the vehicle.




17. Remove the bolts which secure the rear brake hose mounting bracket.




18. Remove the rear brake caliper and tie it to the body side of the vehicle.
19. Remove the parking brake cable from the parking brake assembly.
20. Remove the rear exhaust pipe.
21. Remove the propeller shaft.
22. Remove the heat shield cover.




23. Disconnect the connector from the rear ABS wheel speed sensor.







24. Remove the bolts securing the parking brake cable clamp.
25. Remove the rear suspension assembly.

CAUTION: A helper is required to perform this work.

1. Support the rear differential with the transmission jack.




2. Remove the bolts which hold the rear shock absorber to the rear suspension arm.







3. Remove the bolts which secure the rear suspension assembly to the body.
4. Remove the rear suspension assembly.




26. Disconnect the connector.




27. Disconnect the evaporation hose.




28. Disconnect the fuel filler hose (A) and evaporation hose (B).
29. Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle.






WARNING:
- A helper is required to perform this work.
- Fuel may remain in the side which does not have drain plug of fuel tank. Be careful not to let the fuel tank fall off when removing as it is bad balance on either side.

INSTALLATION
1. Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band.






WARNING: A helper is required to perform this work.

2. Securely insert the fuel filler hose (A) and evaporation hose (B) to the specified position, then tighten the clamp.









Tightening torque: 2.5 N.m (0.25 kgf-m, 1.8 ft-lb)




3. Connect the evaporation hose.
4. Tighten the fuel tank band bolts.

Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)




5. Connect the connector.
6. Install the rear suspension assembly.

CAUTION: A helper is required to perform this work.

1. Support the rear differential with the transmission jack.
2. Support the rear suspension assembly, and tighten the bolts which secure the rear suspension assembly to the body.









Tightening torque:
T1: 125 N.m (12.7 kgf-m, 92.2 ft-lb)
T2: 175 N.m (17.8 kgf-m, 129 ft-lb)

3. Tighten the bolts which hold the rear shock absorber to the rear suspension arm.






Tightening torque: 62 N.m (6.3 kgf-m, 46 ft-lb)

7. Tighten the bolts holding the parking brake cable clamp.






Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)






Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)




8. Connect the connector to the rear ABS wheel speed sensor.
9. Install the heat shield cover.
10. Install the propeller shaft.
11. Install the rear exhaust pipe.
12. Lower the vehicle.
13. Connect the parking brake cable to the parking brake assembly.
14. Install the rear brake caliper.
15. Tighten the bolts which secure the rear brake hose mounting bracket.






Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)

16. Install the rear wheels.

Tightening torque: 120 N.m (12.2 kgf-m, 88.5 ft-lb)




17. Connect the quick connector of the evaporation pipe.




18. Install the pipe protector.
19. Install the trunk room trim. (Sedan model)
20. Install the rear quarter trim. (Wagon model)
21. Connect connector (A) to the fuel sub level sensor.
22. Connect the quick connector of fuel delivery hose (B) and return hose (C).






NOTE: When connecting, be careful not to reverse the delivery side and return side.




23. Install the service hole cover of fuel sub level sensor.




24. Connect connector (A), and install clip (B).




25. Connect the connector to the fuel pump.




26. Install the service hole cover of fuel pump.
27. Install the rear seat.
28. Install the fuse of fuel pump to the main fuse box.




29. Connect the battery ground cable to battery.
30. Inspect the wheel alignment and adjust if necessary.